Miller PHOENIX 456 (575 VOLT) Owner's manual

Brand: Miller

Model: PHOENIX 456 (575 VOLT)

Category: Welding System

Type: Owner's manual

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Processes

OM-186 989C

October 1998

Processes

MIG (GMAW) and Pulsed MIG

(GMAW-P) Welding

Flux Cored (FCAW) Welding

Phoenix 456 CC/CV:

Multiprocess Welding

Description

Invision 456P:

Phoenix 456 CC/CV:

Invision 456P and

Phoenix 456 CC/CV

(575 Volt Models)

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 à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Information sur les champs électromagnétiques 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 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 DIAGRAM 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 -- PARTS LIST 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-186 989

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OM-186 989 Page 1

SECTION 1 -- SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_5/97

1-1. Symbol Usage

Means Warning! Watch Out! There are possible haz-

ards with this procedure! The possible hazards are

shown in the adjoining symbols.

YY Marks a special safety message.

. Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible ELEC-

TRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Con-

sult symbols and related instructions below for necessary actions to

avoid the hazards.

1-2. Arc Welding Hazards

YY The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

seethesymbol, watch out,andfollow therelatedinstructions

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.

YY Only qualified persons should install, operate, maintain, and

repair this unit.

YY During operation,keepeverybody, especially children,away.

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 areelectricallylive.Incorrectly

installed or improperly grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the

work or ground.

D Donotuse AC outputin dampareas,if movementisconfined, orif

there is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on

unit.

D Disconnect input power or stop engine before installing or servic-

ing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its Own-

er’s Manual and national, state, and local codes.

D 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.

D When making input connections, attach proper grounding con-

ductor first -- double-check connections.

D Frequently inspect input power cord for damage or bare wiring --

replace cord immediately if damaged -- bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable -- do not use work clamp or work cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Useonlywell-maintained equipment.Repairor replacedamaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Clamp work cable withgood metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when notconnected to workpiece to prevent

contact with any metal object.

D 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.

D TurnOffinverter, disconnect input power, and discharge input ca-

pacitors according to instructions in Maintenance Section before

touching any parts.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use exhaust at the arc to re-

move welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.

D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

D Workinaconfinedspaceonlyifitiswellventilated,orwhilewear-

ingan air-suppliedrespirator.Alwayshave atrainedwatchperson

nearby. Welding fumes and gases can displace air and lower the

oxygen level causing injury or death. Be sure the breathing air is

safe.

D 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.

D Do not weld on coated metals, such as galvanized, lead, or cad-

mium 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 contain-

ing these elements can give off toxic fumes if welded.

OM-186 989 Page 2

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

ARC RAYS can burn eyes and skin.

D Weara weldinghelmetfitted witha propershadeof filtertoprotect

your face and eyes when welding or watching (see ANSI Z49.1

and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your hel-

met.

D Useprotective screensor barriersto protectothersfrom flashand

glare; warn others not to watch the arc.

D Wearprotectiveclothingmade from durable, flame-resistant ma-

terial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,

drums,orpipes, can causethemto blow up.Sparks

can fly off from the welding arc. The flying sparks,

hot workpiece, and hot equipment can cause fires

and burns. Accidental contact of electrode to metal objects can

cause sparks, explosion, overheating, or fire. Check and be surethe

area is safe before doing any welding.

WELDING can cause fire or explosion.

D Protect yourself and others from flying sparks and hot metal.

D Do not weld where flying sparks can strike flammable material.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition

can cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, orpipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut offweldingwireatcon-

tact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding,chipping, wirebrushing,and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use ap-

proved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun or

torch.

MAGNETICFIELDScan affect pacemakers.

D Pacemaker wearers keep away.

D Wearersshould consult theirdoctor beforego-

ing near arc welding, gouging, or spot welding

operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode.

Since gascylindersarenormally part of the welding

process, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protectcompressed gascylindersfrom excessiveheat,mechan-

ical shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electricalcircuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder -- explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and

fittings designed for the specific application; maintain them and

associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keepprotectivecap in placeovervalveexcept when cylinder is in

use or connected for use.

D Readandfollow instructions oncompressedgas cylinders, asso-

ciated equipment, and CGA publication P-1 listed in Safety

Standards.

OM-186 989 Page 3

1-3. Additional Symbols for Installation, Operation, and Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring -- be sure power supply system

is properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Useequipmentofadequate capacity to lift and

support unit.

D If using lift forks to moveunit, be sure forks are

longenough toextend beyondopposite sideof

unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE han-

dling boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with elec-

tronic equipment perform this installation.

D The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the

installation.

D If notified by the FCC about interference, stop using the equip-

ment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut,

keep spark gaps at correct setting, and use grounding and

shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as com-

puters and computer-driven equipment such

as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Besurethiswelding machine is installed and groundedaccord-

ing to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-

dent of Documents, U.S. Government Printing Office, Washington,

D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and

Cutting of Containers That Have HeldHazardous Substances, Ameri-

can Welding Society Standard AWS F4.1, from American Welding

Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

P-1, from Compressed Gas Association, 1235 Jefferson Davis High-

way, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

CanadianStandardsAssociation,StandardsSales,178 RexdaleBou-

levard, Rexdale, Ontario, Canada M9W 1R3.

SafePractices ForOccupationAndEducationalEyeAndFaceProtec-

tion, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-186 989 Page 4

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables,will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National Re-

search Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure topower-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to beex-

amined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following proce-

dures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as pos-

sible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If clearedbyyourdoctor,

then following the above procedures is recommended.

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OM-186 989 Page 8

1-4. Principales normes de sécurité

Safety in Welding and Cutting, normeANSI Z49.1, de l’American Wel-

ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent

of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe PracticeforthePreparation for Welding andCut-

ting of Containers That Have Held Hazardous Substances, norme

AWSF4.1, de l’American Welding Society,550 N.W.LejeuneRd,Mia-

mi FL 33126

National Electrical Code, NFPA Standard 70, de la National Fire Pro-

tection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

P-1, de la Compressed Gas Association, 1235 Jefferson Davis High-

way, Suite 501, Arlington, VA 22202.

Règles de sécurité en soudage, coupage et procédés connexes, nor-

meCSAW117.2,del’Association canadiennede normalisation,vente

de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W

1R3.

SafePractices ForOccupationAndEducationalEyeAndFaceProtec-

tion, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, dela National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme,

des champs magnétiques basse fréquence

L’extraitsuivant est tirédesconclusions générales dudocumentintitu-

lé Biological Effects of Power Frequency Electric & Magnetic Fields --

Background Paper, OTA--BP--E--53 (Washington DC : U.S. Govern-

ment Printing Office, mai 1989), publié par le Office of Technology

Assessment du Congrès américain : «... il existe maintenant d’abon-

dantes données scientifiques compilées à la suite d’expériences sur

la cellule ou d’études sur des animaux et des humains, qui montrent

clairementque leschampsélectromagnétiques bassefréquencepeu-

vent avoir des effets sur l’organisme et même y produire des

transformations. Même s’il s’agit de travaux de trèsgrandequalité,les

résultats sont complexes. Cette démarche scientifique ne nous per-

met pas d’établir un tableau d’ensemble cohérent. Pire encore, elle ne

nous permet pas de tirer des conclusions finales concernant les ris-

ques éventuels, ni d’offrir des conseils sur les mesuresà prendre pour

réduire sinon éliminer les risques éventuels». (Traduction libre)

Afin de réduire les champsélectromagnétiques dans l’environnement

de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur.

3 Ne pas courber pas et ne pas entourer pas les câbles autour de

vous.

4 Garder le poste de soudage et les câbles le plus loin possible

de vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Lesconsignes mentionnéesprécédemment fontpartie decelles desti-

nées aux personnes ayant recours à un stimulateur cardiaque.

Veuillez consulter votre médecin pour obtenir plus de détails.

OM-186 989 Page 9

SECTION 2 – INSTALLATION

Unless otherwise noted, the Invision 456P is shown throughout this manual.

NOTE

2-1. Specifications

Input

Power

Rated Welding

Out

Amperage

Range

(Phoenix

456 CC/

Voltage

Ran

Maximum

Open-Circuit

Voltage DC

Amperes Input At Rated

Load Output 60 Hz,

Three-Phase

Power

456 CC/

CV Only)

Range

Voltage DC

575 V KVA KW

Three

Phase

450 A @ 38 Volts DC, 100%

Duty Cycle;

565 A @ 43 Volts DC,

60% Duty Cycle

5 – 600 10 – 38 95

24.4

(0.12*)

24.3

(0.12*)

19.0

(0.07*)

*While idling

2-2. Duty Cycle and Overheating

Duty Cycle is percentage of 10

minutes that unit can weld at rated

load without overheating.

If unit overheats, thermostat(s)

opens, output stops, and cooling

fan runs. Wait fifteen minutes for

unit to cool. Reduce amperage or

duty cycle before welding.

Y Exceeding duty cycle can

damage unit and void war-

ranty.

Overheating

A/V

Reduce Duty Cycle

Minutes

duty1 4/95 – SA-181 560

Continuous Welding

100% Duty Cycle At 450 Amperes 60% Duty Cycle At 565 Amperes

6 Minutes Welding 4 Minutes Resting

OM-186 989 Page 10

2-3. Volt-Ampere Curves

Volt-ampere curves show mini-

mum and maximum voltage and

amperage output capabilities of

unit. Curves of other settings fall

between curves shown.

va_curve1 4/95 – SA-181 561 / SA-181 562

Phoenix 456 (CC Only)

Invision 456P and Phoenix 456 (CV Only)

OM-186 989 Page 11

2-4. Dimensions And Weight

Hole Layout Dimensions

A 14-21/64 in (363.9 mm)

B 20-3/4 in (527.1 mm)

28 in

C 23-27/64 in (594.9 mm)

(711 mm)

D 24-31/32 in (634.2 mm)

18 in

(457 mm)

E 12-3/8 in (314.3 mm)

F 9/32 in (7.1 mm) Dia.

Weight

15-1/2 in

(394 mm)

118 lb (53.5 kg)

2-5. Selecting a Location

loc_2 3/96 - ST-800 611 / Ref. ST-801 718

1 Lifting Forks

Use lifting forks to move unit.

Extend forks beyond opposite side

of unit.

2 Lifting Handles

Use handles to lift unit.

3 Hand Cart

Use cart or similar device to move

unit.

4 Rating Label

Use rating label to determine input

power needs.

5 Line Disconnect Device

Locate unit near correct input pow-

er supply.

Y Special installation may be

required where gasoline or

volatile liquids are present –

see NEC Article 511 or CEC

Section 20.

Movement

Location

18 in

(460 mm)

18 in

(460 mm)

Y Do not move or operate

unit where it could tip.

Tipping

OM-186 989 Page 12

2-6. Weld Output Terminals and Selecting Cable Sizes

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Weld Output

Terminals

Welding

Amperes

10 – 60%

Duty Cycle

60 – 100%

Duty Cycle

10 – 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

Positive

(

)

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

(+)

Negative

(–)

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

()

600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0

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. S-0007-D

2-7. Remote 14 Receptacle Information

Socket* Socket Information

24 VOLTS AC

A 24 volts ac. Protected by circuit breaker CB2.

Ref. ST-801 718

VOLTS

B Contact closure to A completes 24 volts ac con-

tactor control circuit.

115 VOLTS AC

I 115 volts ac. Protected by circuit breaker CB1.

115

VOLTS

J Contact closure to I completes 115 volts ac con-

tactor control circuit.

C Output to remote control; +10 volts dc in MIG

mode. For Phoenix 456 only: 0 to +10 volts dc in

other modes.

REMOTE

D Remote control circuit common.

REMOTE

CONTROL

E 0 to +10 volts dc input command signal from re-

mote control.

M Mode select.

N Remote inductance control.

A/V

AMPERAGE

F Current feedback; +1 volt dc per 100 amperes.

AMPERAGE

VOLTAGE

H Voltage feedback; +1 volt dc per 10 arc volts.

GND

G Circuit common for 24 and 115 volts ac circuits.

GND

K Chassis common.

*The remaining sockets are not used.

OM-186 989 Page 13

2-8. 115 Volts AC Duplex Receptacle And Circuit Breakers

ST-801 524-B

1 115 V 10 A AC Receptacle

Power is shared between duplex

receptacle and Remote 14 recep-

tacle (see Section 2-7).

2 Circuit Breaker CB1

3 Circuit Breaker CB2

CB1 protects duplex receptacle

and 115 volts ac portion of Remote

14 receptacle from overload.

CB2 protects 24 volts ac portion of

Remote 14 receptacle from over-

load.

Press button to reset breaker.

2 3

2-9. Electrical Service Guide

Three-Phase

Input Voltage 575

Input Amperes At Rated Output 24.4

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 35

Min Input Conductor Size In AWG/Kcmil 10

Max Recommended Input Conductor Length In Feet (Meters) 371 (113)

Min Grounding Conductor Size In AWG/Kcmil 10

Reference: 1993 National Electrical Code (NEC). S-0092J

OM-186 989 Page 14

2-10. Connecting Input Power

ST-801 535-B / ST-801 822

Y Turn Off welding power

source, and check voltage

on input capacitors accord-

ing to Section 4-3 before

proceeding.

1 Strain Relief Connector

Clamp

Obtain and install proper connec-

tor.

2 Input And Grounding

Conductors

Select size and length using Sec-

tion 2-9. Connect as shown in il-

lustration.

3 Line Disconnect Device

See Section 2-9.

Reinstall right side panel.

Tools Needed:

5/16 in

Contactor W1

L1 L2 L3

= GND/PE

Y Always connect grounding

conductor first.

Connections For

Standard Model

OM-186 989 Page 15

SECTION 3 – OPERATION

3-1. Front Panel Controls For Invision 456P

1 Power Switch

The fan motor is thermostatically con-

trolled and only runs when cooling is

needed.

2 Voltmeter (see Section 3-3)

3 Ammeter (see Section 3-3)

4 Voltage Adjustment Control

5 Inductance Control

Inductance determines the “wetness” of the

weld puddle. When set higher, “wetness”

(puddle fluidity) increases.

23 4

ST-180 306-C

3-2. Mode and Voltage Control For Invision 456P

1 Remote 14 Receptacle

Mode Control

The unit defaults to standard MIG

mode. When a suitable external

pulsing control is attached to the

Remote 14 receptacle, the remote

pendant controls whether the unit

is in standard MIG or pulsed MIG

mode. When the pulsing control is

disconnected, the unit returns to

standard MIG operation.

Voltage Control

The unit defaults to Panel control of

output voltage. When a suitable re-

mote voltage control or pulsing

control is attached to the Remote

14 receptacle, the remote device

assumes control of output voltage.

To return to Panel control of volt-

age, disconnect or disable any re-

mote devices that send an input to

pin E.

ST-801 192

OM-186 989 Page 16

3-3. Meter Functions For Invision 456P

The meters display the actual weld output values for approximately three seconds

after the arc is broken.

NOTE

Mode Meter Reading At Idle Meter Reading While Welding

MIG

Preset Volts Blank

24.5

Actual Volts Actual Amps

24.5 250

Pulsed

MIG

Pulse Display Pulse Display

PPP PPP

Actual Volts Actual Amps

24.5 250

3-4. Front Panel Controls For Phoenix 456 CC/CV

1 Power Switch

The fan motor is thermostatically con-

trolled and only runs when cooling is

needed.

2 Voltmeter (see Section 3-5)

3 Ammeter (see Section 3-5)

4 V/A (Voltage/Amperage) Adjust Control

5 Voltage/Amperage Control Switch

For front panel control, place switch in Panel

position and use the V/A Adjust control.

For remote control, make connections to Re-

mote 14 receptacle, and place switch in Re-

mote position. In most modes, remote control

is a percent of the V/A Adjust control setting.

Value selected on V/A Adjust is maximum

available on remote. In the MIG mode, remote

control provides full range of unit output re-

gardless of V/A Adjust control setting.

6 Mode Switch

The Mode switch setting determines both the

process and output On/Off control (see Sec-

tion 3-6). Source of control (panel or remote)

for the amount of output is selected on the V/A

Control switch.

For Air Carbon Arc (CAC-A) cutting and goug-

ing, place switch in the Stick position. For best

results, place Inductance/Dig control in the

maximum position.

7 Inductance/Dig Control

Control adjusts Dig when the Stick or CC

mode is selected on the Mode switch. When

set towards minimum, short-circuit amperage

at low arc voltage is the same as normal weld-

ing amperage.

When set towards maximum, short-circuit am-

perage is increased at low arc voltage to assist

with arc starts as well as reduce sticking while

welding (see volt-ampere curves in Section

2-3).

Select setting best suited for application.

Control adjusts inductance when MIG position

is selected on the Mode switch. Inductance

determines the “wetness” of the weld puddle.

When set towards maximum, “wetness”

(puddle fluidity) increases.

When Pulsed MIG, or one of the TIG modes is

selected, this control is not functional.

ST-179 842-B

OM-186 989 Page 17

3-5. Meter Functions For Phoenix 456 CC/CV

The meters display the actual weld output values for approximately three seconds

after the arc is broken.

NOTE

Mode Meter Reading At Idle Meter Reading While Welding

Lift-Arc TIG

Actual Volts Preset Amps

7.0 85

Actual Volts Actual Amps

10.3 85

TIG

Blank Preset Amps

Actual Volts Actual Amps

10.3 85

MIG

Preset Volts Blank

24.5

Actual Volts Actual Amps

24.5 250

Pulsed

MIG

Pulse Display Pulse Display

PPP PPP

Actual Volts Actual Amps

24.5 250

Blank Preset Amps

Actual Volts Actual Amps

24.5 85

Stick

Actual Volts (OCV) Preset Amps

80.0 85

Actual Volts Actual Amps

24.5 85

3-6. Mode Switch Settings For Phoenix 456 CC/CV

The Stick and CC modes provide the

Adaptive Hot Start

feature, which

automatically increases the output amperage at the start of a weld should the start

require it. This eliminates electrode sticking at arc start.

NOTE

Mode Switch Setting

Process

O tp t On/Off Control

Mode Switch Setting Process Output On/Off Control

Lift-Arc TIG GTAW – See Section 3-7 Electrode Hot

TIG

GTAW With HF Unit, Pulsing Device,

Or Remote Control

At Remote 14

MIG GMAW At Remote 14

Pulsed MIG GMAW-P (Requires an external pulsing device.) At Remote 14

CC Stick (SMAW) With Remote On/Off At Remote 14

Stick SMAW Electrode Hot

OM-186 989 Page 18

3-7. Lift-Arc TIG Procedure For Phoenix 456 CC/CV

With Mode switch in the Lift-Arc

TIG position, start an arc as fol-

lows:

1 TIG Electrode

2 Workpiece

Touch tungsten electrode to work-

piece at weld start point, hold elec-

trode to workpiece for 1-2 sec-

onds, and slowly lift electrode. An

arc will form when electrode is

lifted.

Normal open-circuit voltage is not

present before tungsten electrode

touches workpiece; only a low

sensing voltage is present be-

tween electrode and workpiece.

The solid-state output contactor

does not energize until after elec-

trode is touching workpiece. This

allows electrode to touch work-

piece without overheating, stick-

ing, or getting contaminated.

1 – 2

Seconds

“Touch”

Do NOT Strike Like A Match!

Ref. S-156 279

SECTION 4 – MAINTENANCE AND TROUBLESHOOTING

Y Disconnect power

before maintaining.

Maintain more often

during severe conditions.

4-1. Routine Maintenance

3 Months

Replace

damaged or

unreadable

label.

Repair or

replace

cracked

cables.

Replace

cracked

torch body.

Repair or

replace cracked

cables and cords.

6 Months

Clean and

tighten weld

terminals.

Blow out

inside.

OM-186 989 Page 19

4-2. Blowing Out Inside of Unit

Y Do not remove case when

blowing out inside of unit.

To blow out unit, direct airflow

through front and back louvers as

shown.

Ref. ST-801 718

OM-186 989 Page 20

4-3. Removing Case and Measuring Input Capacitor Voltage

Turn Off welding power source,

and disconnect input power.

1 Right Side Panel

To remove panel, remove screws

securing panel to unit.

2 Interconnect Board PC2

3 Voltmeter

Measure the dc voltage across the

screw terminals on PC2 as shown

until voltage drops to near 0 (zero)

volts.

Proceed with job inside unit. Rein-

stall cover when finished.

Tools Needed:

5/16 in

Ref. ST-801 718 / Ref. ST-801 536-A

Y Significant DC voltage can remain on capacitors

after unit is Off. Always check the voltage as shown

to be sure the input capacitors have discharged be-

fore working on unit.

+ lead to lower right

terminal, – lead to

upper right terminal

OM-186 989 Page 21

4-4. Voltmeter/Ammeter Help Displays

All directions are in reference

to the front of the unit. All cir-

cuitry referred to is located in-

side the unit.

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.

2 Help 2 Display

Indicates a malfunction in the ther-

mal protection circuitry located on

the left side of the unit. If this dis-

play is shown, contact a Factory

Authorized Service Agent.

3 Help 3 Display

Indicates the left side of the unit

has overheated. The unit has shut

down to allow the fan to cool it (see

Section 2-2). Operation will contin-

ue when the unit has cooled.

4 Help 4 Display

Indicates a malfunction in the ther-

mal protection circuitry located on

the right side of the unit. If this dis-

play is shown, contact a Factory

Authorized Service Agent.

5 Help 5 Display

Indicates the right side of the unit

has overheated. The unit has shut

down to allow the fan to cool it (see

Section 2-2). Operation will contin-

ue when the unit has cooled.

6 Help 6 Display

Indicates that the input voltage is

too low and the unit has automati-

cally shut down. Operation will

continue when the voltage is within

±15% of the operating range. If this

display is shown, have an electri-

cian check the input voltage.

7 Help 7 Display

Indicates that the input voltage is

too high and the unit has automati-

cally shut down. Operation will

continue when the voltage is within

±15% of the operating range. If this

display is shown, have an electri-

cian check the input voltage.

8 Help 8 Display

Indicates a malfunction in the sec-

ondary power circuit of the unit. If

this display is shown, contact a

Factory Authorized Service Agent.

HE.L P–1

HE.L P–2

HE.L P–3

HE.L P–4

HE.L P–5

HE.L P–6

HE.L P–7

HE.L P–8

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Model: PHOENIX 456 (575 VOLT)

Category: Welding System

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